Electric-powered, closed-loop, continuous-feed, endothermic energy-conversion systems and methods

ABSTRACT

Electric-powered, closed-loop, continuous-feed, endothermic energy-conversion systems and methods are disclosed. In one embodiment, the presently disclosed energy-conversion system includes a shaftless auger. In another embodiment, the presently disclosed energy-conversion system includes a drag conveyor. In yet another embodiment, the presently disclosed energy-conversion system includes a distillation and/or fractionating stage. The endothermic energy-conversion systems and methods feature mechanisms for natural resource recovery, refining, and recycling, such as secondary recovery of metals, minerals, nutrients, and/or carbon char.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation and claims priority to U.S. patentapplication Ser. No. 17/409,159 filed Aug. 23, 2021, which is acontinuation and claims priority to U.S. patent application Ser. No.16/622,684 filed Dec. 13, 2019 (now U.S. Pat. No. 11,097,245), which isa 35 U.S.C. § 371 U.S. National Phase entry of International ApplicationNo. PCT/US2018/037445 entitled “Electric-Powered, Closed-Loop,Continuous-Feed, Endothermic Energy-Conversion Systems and Methods”having an international filing date of Jun. 14, 2018, which claims thebenefit of U.S. Provisional Patent Application Ser. No. 62/519,213 filedJun. 14, 2017, the entire disclosures of which are incorporated hereinby reference.

TECHNICAL FIELD

The presently disclosed subject matter relates generally toenergy-conversion processes and more particularly to electric-powered,closed-loop, continuous-feed, endothermic energy-conversion systems andmethods.

BACKGROUND

Current energy-conversion processes, such as incineration, gasification,fluidized beds, updraft, downdraft, and low-temperature pyrolysis, allresult in heavily regulated air emissions, waste water effluents, and/orother by-products, which can often limit the operating parameters andpermitting of the system.

Further, current energy-conversion processes, such as incinerationbio-digesters, low-temperature pyrolysis, and gasification systems,focus primarily on the capture of bio-gases yet only recover a smallfraction of the available energy, and only minimally reduce the volumeof feedstock solids, if at all. Conventional systems operate in heatranges that cannot isolate metals, minerals, and nutrients in a reusableformat. Consequently, the residuals must be landfilled or land applied,which is highly regulated if not prohibited in many jurisdictions.Disposal is further complicated by the presence of hazardouscontaminates, medical residuals, and pathogens. Accordingly, there areboth regulatory and financial implications with regard to disposal ofthese solids.

SUMMARY

In accordance with a first aspect of the present invention there areprovided systems and methods for energy conversion. The systems andmethods may include electric-powered, closed-loop, continuous-feed,endothermic energy-conversion systems and methods featuring mechanismsfor natural resource recovery, refining, and/or recycling, such assecondary recovery of metals, minerals, nutrients, and/or carbon char.

Certain embodiments of the invention envisage a system comprising: acontroller; a reactor managed by the controller; a shaftless auger inthe reactor; and a heater surrounding the reactor and shaftless auger,wherein the system is closed-loop. In other embodiments, the system mayfurther include components such as a scale, mixer, feedstock hopermetering stage, infeed sensor, and airlock. In still other embodiments,the system may include a compensator for maintaining pressure within thereactor. In yet other embodiments, the system may include a vaporpre-heating stage, a ceramic hot gas filter, a quench stage, apass-through multi-tube plunging condenser, a compensator with anassociated recirculator, a vacuum buffer tank, a regulator, a vacuumpump, a syngas buffer tank, and a catalytic scrub. Further, the systemmay include an automated plunging system. Still further, the system mayinclude a pressure transition component.

In other embodiments, the system of the present invention may include adrag conveyor instead of a shaftless auger as described above. Thisembodiment may include an airlock with a high-temperature fluid bath. Instill other embodiments, the system may include a multi-zone quenchstation and atmosphere fractioning unit.

Certain embodiments of the present invention envisage a method that mayinclude, but is not limited to, the following steps: providing anenergy-conversion system as described above; supplying feedstockmaterial to the energy-conversion system; processing the feedstockmaterial; supplying the processed feedstock material to the inlet of thereactor; advancing the processed feedstock through the reactor while thereactor facilitates a phase-change process of the feedstock from solidto liquid to vapor; maintaining through multi-zone heater accurate andconsistent temperature within reactor; maintaining a positive pressurein the system; discharging from reactor outlets char and vapor obtainedfrom reacted feedstock; removing particulates from the discharged vapor;quenching discharged vapor to prevent tar, grease, and/or wax build-ups;after quenching step, transitioning from the positive pressure to anegative pressure in the system; supplying the quenched vapor to avacuum buffer tank; removing liquid from the vapor cooling the vaporperforming a filter-less quenching gas clean-up operation anddischarging syngas; and balancing the energy-conversion system through aclosed-loop.

Other aspects and features of the present invention will become evidentfrom a review of the Drawing and Detailed Description provided.

BRIEF DESCRIPTION OF DRAWINGS

Having thus described the presently disclosed subject matter in generalterms, reference will now be made to the accompanying Drawings, whichare not necessarily drawn to scale, and wherein:

FIG. 1 illustrates a block diagram of an energy-conversion system thatincludes a shaftless auger, according to one embodiment of the presentlydisclosed electric-powered, closed-loop, continuous-feed, endothermicenergy-conversion system;

FIG. 2 illustrates a block diagram of an energy-conversion system thatincludes a drag conveyor, according to another embodiment of thepresently disclosed electric-powered, closed-loop, continuous-feed,endothermic energy-conversion system;

FIG. 3 illustrates a block diagram of an energy-conversion system thatincludes a distillation and/or fractionating stage, according to yetanother embodiment of the presently disclosed electric-powered,closed-loop, continuous-feed, endothermic energy-conversion system;

FIG. 4 through FIG. 25 show various views of one example instantiationof the shaftless auger-based energy-conversion system shown in FIG. 1 ;

FIG. 26 illustrates a flow diagram of an example of a method ofoperation of the shaftless auger-based energy-conversion system shown inFIG. 1 ; and

FIG. 27 through FIG. 56 show various views of one example instantiationof the drag conveyor-based energy-conversion system shown in FIG. 2 .

DETAILED DESCRIPTION

The presently disclosed subject matter now will be described more fullyhereinafter with reference to the accompanying Drawings, in which some,but not all embodiments of the presently disclosed subject matter areshown. Like numbers refer to like elements throughout. The presentlydisclosed subject matter may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Indeed, many modifications andother embodiments of the presently disclosed subject matter set forthherein will come to mind to one skilled in the art to which thepresently disclosed subject matter pertains having the benefit of theteachings presented in the foregoing descriptions and the associatedDrawings. Therefore, it is to be understood that the presently disclosedsubject matter is not to be limited to the specific embodimentsdisclosed and that modifications and other embodiments are intended tobe included within the scope of the appended claims.

In some embodiments, the presently disclosed subject matter provideselectric-powered, closed-loop, continuous-feed, endothermicenergy-conversion systems and methods. The presently disclosedendothermic energy-conversion systems and methods feature mechanisms fornatural resource recovery, refining, and recycling, such as secondaryrecovery of metals, minerals, nutrients, and/or carbon char.

In one embodiment, the presently disclosed electric-powered,closed-loop, continuous-feed, endothermic energy-conversion systemincludes a shaftless auger. In another embodiment, the presentlydisclosed electric-powered, closed-loop, continuous-feed, endothermicenergy-conversion system includes a drag conveyor. In yet anotherembodiment, the presently disclosed electric-powered, closed-loop,continuous-feed, endothermic energy-conversion system includes adistillation and/or fractionating stage or component. In still anotherembodiment, the presently disclosed electric-powered, closed-loop,continuous-feed, endothermic energy-conversion system includes acatalytic-heated reactor.

In some embodiments, the presently disclosed endothermicenergy-conversion systems and methods provide a positive energy balance.For example, in the endothermic energy-conversion systems and methods,any feedstock that is about >3000 BTU/pound dry basis will result inpositive net energy.

In some embodiments, the presently disclosed endothermicenergy-conversion systems and methods is substantially emissions-freeand provides substantially effluent-free conversion of animal-waste,bio-mass, coal, rubber and/or municipal-solid-waste into renewableenergy formats including syngas, gasoline, diesel, electricity. Namely,the presently disclosed endothermic energy-conversion systems andmethods provide a closed-loop system that has substantially no airemissions/pollution, waste water effluent/pollution, and produces noadditional unmarketable products. As a result, there may be few or noregulatory constraints on operations and permitting.

In some embodiments, the presently disclosed endothermicenergy-conversion systems and methods has capability to recover thenon-energy fraction of the feedstock into a prescriptive carbon-charthat has commercial re-sale value as a soil amendment, an animal feedsupplement, or as a filtration media. Further, it has capability torecover the liquid condensable fraction of the conversion process.Further, it allows marketing and selling commercially recovered productwhere possible and refining product to allow re-sale into the marketwhere needed. Further, the non-condensable fraction of the conversionprocess can be fractionated into a producer gas.

In some embodiments, the presently disclosed endothermicenergy-conversion systems and methods may: (1) reduce feedstock volumeby up to about 85% while preserving the resident metals, minerals, andnutrients; (2) condense the residual metals, minerals, and nutrientsinto a pathogen-free, medical residual-free carbon char that can befurther fractionated into its component parts; (3) because of thereduced feedstock volume, minimize shipping expense and maximizere-sale/radius; (4) provide substantially pathogen-free, medicalresidual-free status that reduces or entirely eliminates regulatorybarriers to beneficial reuse or use in whole as an animal feedsupplement or a soil amendment to minimize with no regulatory constrainton commercial re-sale; (5) provide improved economics of charrecycling/re-sale, which allows for an economically viableself-sustaining renewable energy loop; and (6) receive the residualsfrom current energy-conversion systems and process them as a feedstock.

In some embodiments, the presently disclosed endothermicenergy-conversion systems and methods require no-landfilling orland-application of residuals. Namely, the system may allow for fullconversion of substantially the entire feedstock by convertingsubstantially all volatiles into renewable energy and then reformattingthe residuals metals, minerals, and nutrients into byproducts withcommercially viable beneficial extended life reuse. For example, thepresently disclosed endothermic energy-conversion systems and methodsmay: (1) reduce or entirely eliminate the need for landfilling or landapplication of residuals; (2) reduce or entirely eliminate the expenseof landfilling; (3) reduce or entirely eliminate regulatory burden andexpense; and (4) be used to clean up large stockpiles of residual wastefrom existing current energy-conversion systems.

Referring now to FIG. 1 is a block diagram of an energy-conversionsystem 100 that includes a shaftless auger, according to one embodimentof the presently disclosed electric-powered, closed-loop,continuous-feed, endothermic energy-conversion system. Energy-conversionsystem 100 is typically a closed-loop system that (1) eliminatessubstantially all emissions and effluents; (2) recovers substantiallyall residual carbon, metals, minerals, and nutrients for beneficialreuse; (3) reuses residual/waste heat; and (4) reduces or entirelyeliminates parasitic loss of potential energy.

Energy-conversion system 100 includes a controller 105. Controller 105is used to manage the overall operations of energy-conversion system100. Controller 105 can be any computing device that is capable ofexecuting program instructions. Controller 105 can be, for example, aserver, a desktop computer, a laptop computer, a tablet device, asmartphone, a smartwatch, a cloud computing device, and the like.

Energy-conversion system 100 also includes a reactor 110, also known asa conversion chamber or conversion reactor. Reactor 110 is anelectrically controlled and heated reactor. Reactor 110 is typically apipe or tube that is equipped with multi-zoned electric heat. Namely, ashaftless auger 112 is installed in reactor 110. Further, a multi-zoneheater 114 surrounds the assembly of the reactor 110 and shaftless auger112. In one example, reactor 110 is a pipe or tube that is about 30 feet(about 9.1 meters) long and about 12 inches (about 30.48 cm) indiameter. However, reactor 110 can be any length and diameter and theshaftless auger 112 can be sized accordingly. Namely, the length ofreactor 110 may be determined by the amount of residence time needed inthe system. Further, reactor 110 can be formed, for example, of carbonsteel, stainless steel, or specialized alloys, such as, but not limitedto, selected Inconel alloys (i.e., a family of austeniticnickel-chromium-based superalloys).

Conventional continuous-feed energy-conversion systems often utilizeshafted auger systems that are problematic with exposure to high heat.In these systems, the shafted auger is aligned and centered withbearings at both ends of the conversion chamber, as the auger issubjected to heat creep or thermal growth occurs. The conversion chamber(i.e., the pipe), shaft, and flights may expand (i.e., thermalexpansion) at different rates. This creates alignment problems becausethe shaft expands slower than the flights and therefore the shaft oftenexperiences warping. The shaft additionally carries the weight of theauger and when subjected to heat will sag or deflect depending on thelength. Further, in conventional systems, the weld connections betweenthe flight and shaft also are stressed with creep and will ultimatelyfail. Tolerances from pipe to flight on the shafted auger have to beadequate to allow rotation in the presence of a warping and/or saggingshaft.

The inclusion of shaftless auger 112 in energy-conversion system 100mitigates many of the problems associated with shafted augers. Namely,shaftless auger 112 is designed to rotate in direct contact to reactor110 (i.e., the pipe or trough) and, at elevated temperature, canexperience galling. Shaftless auger 112 is allowed to be supported bythe pipe, which ensures alignment and removes the length limitationcreated by weight. Additionally, centering shaftless auger 112 on thenon-drive-end of shaftless auger 112 is eliminated, which allowsshaftless auger 112 to experience creep growth with no effect onbearings or seals. Shaftless auger 112 being in direct contact with theinner walls of reactor 110 (i.e., the pipe or trough) also promotesscouring and maintaining of direct surface contact with feedstock,thereby ensuring thermal conductivity. The mass of auger 112 being indirect contact with reactor 110 (i.e., the pipe or trough) alsoincreases thermal conductive surface area, which ensures high conductionrate of heat energy to feedstock.

Shaftless auger 112 is typically a single penetration auger that reduceswear and tear on bearings and seals as compared with multiplepenetration augers of conventional conversion chambers. Shaftless auger112 is in direct contact with the inner walls of reactor 110 (i.e., thepipe or trough), which increases scouring and self-cleaning as comparedwith augers of conventional conversion chambers that have no contactwith the pipe and provide minimal scouring. Shaftless auger 112 ensureshigh thermal conduction and energy efficiency by substantiallyeliminating deposited material between reactor 110 and shaftless auger112. Because there is no shaft, shaftless auger 112 eliminatesdifferential growth rates between shaft and flights which cause metalfatigue and failure. Because there is no shaft, shaftless auger 112eliminates chronic issues that conventional conversion chambers havewith respect to warping of the shaft. Because there is no shaft,shaftless auger 112 eliminates high-heat weld failure on the auger asthere is no need to connect flights to the shaft. Shaftless auger 112allows fixed creep and growth direction of the auger in reactor 110without a second penetration point. Shaftless auger 112 can be formed ofspecialized alloys, such as, but not limited to, selected Inconelalloys, and protected with dissimilar alloy wear strips to preventgalling of similar metals with direct contact of the auger to the pipeor trough. Galling is adhesive wear caused by microscopic transfer ofmaterial between metallic surfaces, during transverse motion/sliding.Galling occurs frequently whenever metal surfaces are in contact,sliding against each other, especially with poor lubrication. Also,shaftless auger 112 can be formed of the specialized alloys (e.g.,Inconel 625 alloys) to prevent chlorine migration and hydrogenembrittlement. However, in other embodiments, shaftless auger 112 can beformed of carbon steel or stainless steel. Shaftless auger 112 createsan agitating and stirring effect of the feedstock, which facilitatesmore efficient heat distribution.

Using multi-zone heater 114, reactor 110 is an electric heat conversionchamber; namely, a multi-zone electrically heated oven. In one example,multi-zone heater 114 provides six (6) individually controlled heatingzones within reactor 110. Multi-zone heater 114 provides heat energy forboth start-up and the feedstock conversion process. Multi-zone heater114 provides precisely controlled chamber temperatures for prescriptiveoutcomes, such as pathogen-free and/or medical residual-free. Multi-zoneheater 114 provides for very precise control of temperature bands forprescriptive fractioning and refining of distillates and chars.Multi-zone heater 114 is capable to provide heat ranging from about 100°F. (about 38° C.) to about 2500° F. (about 1371° C.). Multi-zone heater114 provides for substantially instantaneous response to sensor drivenheat demand Using multi-zone heater 114 eliminates air emissions and theneed for an exhaust stack. Using multi-zone heater 114 eliminatesatmospheric heat loss through exhaust stack. Further, the use ofelectric heat in reactor 110 eliminates natural gas or propane emissionsfrom the conversion process. As a result, the use of the electric-heatreactor 110 requires no air permit for the conversion process. Further,reactor 110 in not limited to electric heat only. In another example,reactor 110 can be a catalytically-heated reactor.

Processing the feedstock (or in-feed) that supplies the inlet of reactor110 is a scale 116, a mixer 118, a feedstock hopper metering stage 120,one or more in-feed sensors 122, and an airlock 124.

In energy-conversion system 100, the feedstock can be, in one example,any biomass (i.e., any organic matter or organic waste that can be usedas a fuel), such as, but not limited to, manure, coal, trash, rubber,and plastic. In another example, the feedstock can be mining waste, suchas, but not limited to, mine tailings and water-based and/or oil-baseddrilling mud. However, the system configuration of energy-conversionsystem 100 is particularly well suited for processing “sticky”feedstock, such as rubber and plastic. At the site of energy-conversionsystem 100, the feedstock is typically received at a scale 116 forweighing the bulk feedstock material. The feedstock then enters mixer118. Mixer 118 is used to ensure a homogenous mixture of feedstockentering the system.

Feedstock hopper metering stage 120 is used for metering the feedstockinto reactor 110 at a certain rate. Feedstock hopper metering stage 120can include, for example, an auger-driven metering mechanism and/or abelt-driven conveyor. Further, feedstock hopper metering stage 120functions to pre-heat and dry the feedstock. Accordingly, feedstockhopper metering stage 120 includes a dryer mechanism, such as bed dryerthat allows conduction drying rather than using convection drying withheated air or a combination of both conduction and convection. Drying iscompleted in a closed-loop environmentally friendly manner, whichdramatically slows the heat dissipation and dramatically improves theenergy balance. In feedstock hopper metering stage 120, waste heat canbe captured. Additionally, soluble nutrients can be recaptured withcondensing of vapor from the dryer. Further, hot oil from heat recoverycan be used to dry the feedstock while metering.

Further, feedstock hopper metering stage 120 includes a metered sorbentapplication that can be used for pre-combustion sequestration ofcontaminants, such as sulfur, chlorine, and dioxins. The metered sorbentapplication pre-treats gas while still in the vapor state. Namely,metered sorbents and reagents are added to feedstock prior to or justafter the conversion process to sequester contaminates like sulfur andchlorine. Sorbent and reagents can be, for example, finely milled lime,trona, bentonite, sodium bentonite, sodium, and/or sodium bicarbonate,depending on the contaminate. Sorbents and reagents are subjected tominimum heat to promote active bond to contaminants.

In-feed sensors 122 are used to automatically control feedstockbed-depth and rate into reactor 110, which enables an ultra-efficientconversion of the feedstock. In-feed sensors 122 include a positive flowadvancement sensor that ensures a scouring effect at the inlet ofreactor 110 by the introduction of feedstock at or below reactor level.

The outlet of feedstock hopper metering stage 120 supplies an inlet ofairlock 124, which is a passive airlock that is used to remove the airfrom the feedstock. In airlock 124, feedstock material is advanced via aconical auger. The conical auger compresses the loose materials into atube. The compressing action of the conical auger is the mechanism forremoving the air from the feedstock material. Namely, the conical augerautomatically compresses the loose materials to form about 45pounds/cubic foot (about 720 kilogram/cubic meter) to about 50pounds/cubic foot (about 800 kilogram/cubic meter) density plug/airlock,which enables oxygen-free feedstock supply into reactor 110. The augerautomatically creates an airlock plug with advancing material. Theoutlet of airlock 124 supplies the inlet of reactor 110. Reactor 110 mayhave multiple outlets.

In energy-conversion system 100, the dried and air free, or liquidsoaked and drained feedstock is then processed through reactor 110.Namely, shaftless auger 112 is used to advance the feedstock throughreactor 110. Increased heat transfer rates are achieved by the largeamount of surface contact created by the increased density of feedstockwith liquid increasing the phase-change process to vapor. Feedstock isturned and stirred through reactor 110 to ensure uniform conversionprocess. Continuous process vapor is mixed throughout the process andequalized prior to reaching the outlets. Feedstock exposure to heatenergy is limited to ensure production of a market driven productmeeting end users' specifications. Reactor process pressure is less thanabout 10 inches (about 25.4 cm) of pressure to relieve stress onstructural components, reduce constraints on seals, and to ensure thatno air can enter reactor 110. Pressure is maintained within reactor 110with vapor created in phase change of feedstock and relieved bycompensators (e.g., a primary compensator 136 and a secondarycompensator 140 as described hereinbelow). By contrast, conventionalenergy-conversion systems are designed for positive or negativepressure. The regulation of pressure is challenged with clogging atdischarge, feedstock input process, and even uniform heat throughout thereactor with utilization of burners, augers, and the inability to createand maintain an airtight environment. The presently disclosedenergy-conversion systems can mitigate these drawbacks.

The electric multi-zone heater 114 also allows for extremely accurateconsistent temperature settings for controlled reaction, therebyeliminating the cyclical nature of overheating and then under heatingtypically seen on a reactor with the combustion of product. Thisaccuracy and elimination of cyclical heating increases helps ensureproducts that can meet specifications to allow marketability.

Further, in energy-conversion system 100, the electric generated zonedheat (via multi-zone heater 114) supplies the energy required tofacilitate the conversion process, which allows for a truly closed-loopsystem. Namely, as feedstock progresses through reactor 110, thefeedstock changes from a solid to a liquid and then to a vapor. If thefeedstock has a quantified BTU per given mass, it can be accounted forin the sum of the gas, liquid, and char fractions. By contrast,conventional energy-conversion systems often utilize a percentage of thefeedstock, produced gas, and/or the produced liquid to supply the energyrequired to advance the conversion process. Further, inenergy-conversion system 100, the amount of total energy generated fromthe conversion process is far more than the energy consumed by theprocess. That is, energy-conversion system 100 has a positive energybalance. Namely, in energy-conversion system 100, any feedstock that isabout >3000 BTU/pound (about >6613 BTU/kilogram) dry basis will resultin positive net energy.

Additionally, reactor 110 has a specified “pathogen and medical residualdestruction zone” in which the temperature and duration is controlledand monitored by imbedded electronic sensors (i.e., thermocouples,pressure indicators, and residence time sensors). Information from thesensors can be used to calculate and ensure that the FDA heat exposurestandard of 5-logarithmics iterations for “pathogen-free” and “medicalresidual-free” classifications are achieved, recorded, and storedremotely in triplicate.

Energy-conversion system 100 further includes a vapor pre-heating stage129, a ceramic hot gas filter 130, a first quench stage 132, apass-through multi-tube plunging condenser 133, a second quench stage134, a primary compensator 136 with an associated primary recirculator138, a secondary compensator 140 with an associated secondaryrecirculator 142, a vacuum buffer tank 144, a regulator 146, a vacuumpump 148, a syngas buffer tank 150, and a catalytic scrub 152.

Namely, an outlet of reactor 110 supplies an inlet of vapor pre-heatingstage 129, an outlet of vapor pre-heating stage 129 supplies an inlet ofceramic hot gas filter 130, an outlet of ceramic hot gas filter 130supplies an inlet of first quench stage 132, an outlet of first quenchstage 132 supplies an inlet of multi-tube plunging condenser 133, anoutlet of multi-tube plunging condenser 133 supplies an inlet of secondquench stage 134, an outlet of second quench stage 134 supplies an inletof primary compensator 136, an outlet of primary compensator 136supplies an inlet of a primary recirculator 138, an outlet of a primaryrecirculator 138 supplies an inlet of secondary compensator 140, anoutlet of secondary compensator 140 supplies an inlet of secondaryrecirculator 142, an outlet of secondary recirculator 142 supplies aninlet of vacuum buffer tank 144, an outlet of vacuum buffer tank 144supplies an inlet of regulator 146, an outlet of regulator 146 suppliesan inlet of vacuum pump 148, an outlet of vacuum pump 148 supplies aninlet of syngas buffer tank 150, and an outlet of syngas buffer tank 150supplies an inlet of catalytic scrub 152.

Conventional energy-conversion systems operate in heat ranges thatcannot isolate the metals, minerals, and nutrients in a reusable format.By contrast, energy-conversion system 100 features commoditized naturalresource recovery. Namely, energy-conversion system 100 operates in aheat range that prescriptively chelates or electrostatically bonds thetargeted commodities to the carbon matrix created by the conversionprocess. The resulting char has commercial re-sale value as a soilamendment or and animal feed supplement. For example, energy-conversionsystem 100 produces a char 160 (discharged at an outlet of reactor 110).Generally, any feedstock material that remains solid (i.e., that doesnot turn to vapor) when processed through reactor 110 is discharged aschar 160. Char 160 can be, for example, a solid carbon char and othernutrients that can be sold to market. For example, char 160 can be soldto market as a soil amendment, or due to its pathogen-free, medicalresidual-free status, as a high-end animal feed supplement.

Vapor that is at a critical heat temperature of, for example, from about900° F. (about 482° C.) to about 1000° F. (about 538° C.) exits reactor110 through ceramic hot gas filter 130. Ceramic hot gas filter 130 is amulti-zone ceramic hot gas filter that provides active vapor filtrationto remove any particulate prior to condensing. Ceramic hot gas filter130 allows systematic pulsing for purging of chars and contaminants.Ceramic hot gas filter 130 uses a supply of producer gas for pulsing.Ceramic hot gas filter 130 provides economic advantages by not supplyinginert gas. Pre-heating pulse gas reduces the opportunity for acondensing moment, which would result in tar and/or wax build-up.

The outlets of reactor 110 through which the hot vapor exits utilize anautomated plunging system 128. For example, automated plunging system128 features integrated multi-vapor discharge nozzles, wherein thenozzles may be integrated into filtering (e.g., ceramic hot gas filter130), quenching stages, (e.g., first quench stage 132 and second quenchstage 134), multi-tube plunging condenser 133, and any combinationsthereof. In reactor 110, the nozzles are continuously scoured byautomated plunging system 128, which includes a set of continuous “shaftand shell” pneumatic or hydraulic plungers that are used to scourresidual char deposit to maintain clear pathways for more efficientvapor discharge and collection. Continuous plunging slows gas velocitiesand allows suspended particles to drop out of vapor creating a cleanergas prior to condensation. Reactor 110 features multi-port vapordischarge that is based on automated plunging system 128. The presenceof multi-port plunged vapor outlets ensures vapor discharge at aprescribed maximum velocity.

Maintaining a minimum temperature of entire vapor discharge system tothe first stage of vapor condensing eliminates the opportunity to formand deposit waxes, tars, and/or acids. Conventional energy-conversionsystems rely on vapor to heat the system as the system becomes active.Until the system reaches critical temperature, condensation occurs,thereby allowing deposits and acids to form. Once deposits are formedthe system becomes coated, which promotes clogging and adding to systemdowntime and maintenance. By contrast, in energy-conversion system 100,vapor pre-heating stage 129 (together with ceramic hot gas filter 130)reduces pre-condensing opportunities, minimizes corrosive build-up,reduces tar and wax deposits minimizing clogging opportunities, reducesacidic formation, reduces maintenance expense and downtime, andincreases lifespan of capital equipment. Namely, vapor pre-heating stage129 is used to pre-heat the gas leading into and flowing out of ceramichot gas filter 130 in order to prevent the gases from condensing andclogging ceramic hot gas filter 130. Using vapor pre-heating stage 129,the gas can be heated to from about 450° F. (about 232° C.) to about500° F. (about 260° C.). In operation, in pre-heating stage 129, thevapor is heated by heating the components through which the vapor flows.Heating can be performed, for example, using heat trace tubing, hot oil,and/or steam.

Quenching of vapor with produced liquid fraction product is accomplishedusing first quench stage 132 and second quench stage 134. Quenchingpromotes the elimination of tars, resins, and waxes (i.e., the heavytars or oils) in gas fraction, removes particulate for the vapor stream,and allows for collection of specific fraction of condensable liquid.The vapor can be quenched using, for example, mineral oil or any otheroil that can be used to absorb the tars, resins, and waxes. In someembodiments, quenching liquid can be filtered into a high temperaturefluid bath (HTFB) to recapture nutrient and/or char. Any vapor remainingafter processing by first quench stage 132, multi-tube plungingcondenser 133, and second quench stage 134 is passed to primarycompensator 136 with its primary recirculator 138. Multi-tube plungingcondenser 133 is arranged between first quench stage 132 and secondquench stage 134. Current condensing systems experience deposits ofwaxes, heavy oils, greases and tars. As deposits occur, condensing ratedecreases, creating vapor carry over effects, clogging, highermaintenance costs and ultimately increased downtime. Multi-tube plungingcondenser 133 mitigates these problems. For example, multi-tube plungingcondenser 133 includes an open ended plunged shell and tube heatexchange condenser to eliminate tar, grease, and/or wax build-ups.Supported by automated plunging system 128. Multi-tube plungingcondenser 133 eliminates clogging of waxes, tars and heavy oils;promotes advancement of any condensed liquid; promotes heat transferfrom vapor to condensing tubes; and reduces maintenance and down time.

In energy-conversion system 100, there may be a pressure transitioncomponent. In particular, the system may include a transition from apositive pressure system to a negative pressure system. For example,reactor 110 through first quench stage 132 and second quench stage 134is pressurized to about 7 inches (about 17.78 cm) of water columnpressure. However, at primary compensator 136 the system begins totransition to a negative pressure system. Accordingly, primarycompensator 136 and primary recirculator 138 allow for low-pressurevapor supply to negative pressure vapor removal. Further, primarycompensator 136 acts as condenser that: (1) provides first phasetube-to-shell heat exchange, (2) provides second phase direct contactwith cooling fluid, (3) provides cooling fluid the same as condensableliquid, (4) provides cooling fluid that creates turbulence withmulti-port feed, and (5) allows for specific fraction collection onvapor. In one example, primary compensator 136 includes a tube that isabout 53 inches (about 134.6 cm) tall. The amount of pressure can be setby adjusting the height of the tube. In one example, there is about 46inches (about 116.8 cm) of negative water column pressure at primarycompensator 136. Further, the vapor enters primary compensator 136 andprimary recirculator 138 at about 300° F. (about 149° C.) and exitsprimary compensator 136 and primary recirculator 138 at about 100° F.(about 38° C.) (at about ambient temperature).

Secondary compensator 140 with its secondary recirculator 142 allow forincreased negative pressure vapor removal. Like primary compensator 136,secondary compensator 140 acts as condenser that: (1) provides firstphase tube-to-shell heat exchange, (2) provides second phase directcontact with cooling fluid, (3) provides fluid the same as condensableliquid, (4) provides cooling fluid that creates turbulence withmulti-port feed, and (5) allows for multiple specific fractioncollection on vapor. There is a heat exchange in secondary compensator140 and secondary recirculator 142. Therefore, vapor enters secondarycompensator 140 and secondary recirculator 142 at about 100° F. (about38° C.) (at about ambient temperature) and exits secondary compensator140 and secondary recirculator 142 at about 34° F. (about 1.1° C.) or35° F. (about 1.7° C.). It is important to maintain a temperature abovefreezing in case there is water present.

Accordingly, the primary compensator 136 and the secondary compensator140 allow a continuous flow transition of the reactor vapor frompositive pressure to negative pressure, acting as a system non-cloggingor sticking pressure regulator. At the same time, the compensators actas first stage shell and tube heat exchange condenser and then secondstage direct liquid contact heat exchange with similar circulated liquidbeing condensed. Specific temperature of circulating fluid is maintainedwith heat exchange to promote collection of desired fraction of vapor.Additional fractions and condensing stages can be achieved by placingmultiple compensators in line. Additionally, as consecutive compensatorsare placed in line, vapor will enter the compensator with negativepressure and, as with primary compensator 136, continuous flowtransition will occur but to increased negative pressure while stillcondensing to desired fraction design temperature. Current systemsoperate either at positive or negative pressure and do not have theability to make continuous flow transition. Reactor vapor that has notbeen condensed to it limits can deposit liquids, tars, and waxes,thereby causing sticking, clogging, and regulator failure.

Using primary compensator 136 and primary recirculator 138 and secondarycompensator 140 and secondary recirculator 142, anything that iscondensable is condensed so that vapor only moves on to vacuum buffertank 144. Namely, vapor from secondary recirculator 142 supplies vacuumbuffer tank 144. Reactor gas processing systems, such asenergy-conversion system 100, are designed for continuous even flow.However, the production of vapor is often irregular and the use ofbuffering tanks (e.g., vacuum buffer tank 144) helps even the vapor flowand balance of the system.

Vapor then passes from vacuum buffer tank 144 to vacuum pump 148 viaregulator 146. Regulator 146 is used to precisely control the vacuumlevel. In vacuum pump 148, vacuum is generated by a liquid ringcompressor. Vacuum pump 148 is used to remove liquid from vapor and tocool gas on the pressure side of the vacuum. In vacuum pump 148, thefluid is chilled by heat exchange. In one example, vacuum pump 148 is a15 PSI vacuum pump. In vacuum pump 148, the utilization of a liquid ringcompressor allows the cooling of gas as it is being compressed. Further,in the event that any tars have made it past the condensing process,diesel can be utilized as circulating cooled liquid for maintaining theintegrity of the compressor. The liquid ring compressor of vacuum pump148 requires constant air circulation. Accordingly, the combination ofvacuum buffer tank 144 on the upstream side of vacuum pump 148 and thepressurized syngas buffer tank 150 on the downstream side of vacuum pump148 provides a control loop for balancing the system.

In energy-conversion system 100, filter-less quenching gas cleanup canbe performed using a multi-pass catalytic gas polishing system, such ascatalytic scrub 152. For example, catalytic scrub 152 provides athree-pass catalytic scrub operation. Catalytic scrub 152 is used forscrubbing pre-combusted gas, wherein the gas is easier to scrub whilestill condensed. Catalytic scrub 152 includes a unique vessel (notshown) through which the gas flows. Further, catalytic scrub 152performs a gas polishing operation that ensures high quality gas inwhich sulfur, chlorine, and other gas contaminants have beensubstantially eliminated Catalytic scrub 152 is a gas polishing systemthat incorporates a unique concept, in that it is designed to pass thegas through a multiple chambered system utilizing catalysis previouslyused to scrub or clean post combustion or reaction exhaust gases, yet incatalytic scrub 152 pre-combusted gas is scrubbed. By contrast,conventional gas polishing systems typically flow scrubbed exhaust toatmosphere, not requiring an airtight structure. The polished syngasdischarged from catalytic scrub 152 can be supplied to an electricitygenerator, boiler, heater, and the like. Syngas, or synthesis gas, is afuel gas mixture consisting primarily of hydrogen, carbon, methane,propane, butane, carbon monoxide, and very often some carbon dioxide.

Further, in energy-conversion system 100, the primary compensator 136and the secondary compensator 140 in combination with the vacuum buffertank 144-vacuum pump 148-syngas buffer tank 150 loop is the mechanismused to control the pressure inside reactor 110. For example, thiscontrol loop can be used to hold the pressure inside reactor 110 atabout 7 inches (about 17.78 cm) of water column.

Energy-conversion system 100 provides an emission free process. Namely,because of the absence of combustion of one or more of the productsthere is no requirement for stacks and no emissions created or emitted.In addition to the fact there are no emissions, an additional benefit ofenergy-conversion system 100 is that no loss of energy to the stack ispresent. By contrast, in conventional energy-conversion systems, apercentage of the energy is created from the feedstock and/or theproducts, which creates the requirement for heat exchange. Consequently,capturing 100% of that spent energy is next to impossible, which allowsa large percentage of the energy to escape with the emissions up thestack to the environment.

Referring now to FIG. 2 is a block diagram of an energy-conversionsystem 200 that includes a drag conveyor, according to anotherembodiment of the presently disclosed electric-powered, electric- orcatalytically-heated, closed-loop, continuous-feed, endothermicenergy-conversion system. Energy-conversion system 200 is substantiallythe same as energy-conversion system 100 shown in FIG. 1 except that theshaftless auger is replaced with a drag conveyor. Further, the quenchingportion of energy-conversion system 200 differs from the quenchingportion of energy-conversion system 100.

Like energy-conversion system 100 shown in FIG. 1 , energy-conversionsystem 200 is a closed-loop system that (1) eliminates substantially allemissions and effluents; (2) recovers substantially all residual carbon,metals, minerals, and nutrients for beneficial reuse; (3) reusesresidual/waste heat; and (4) eliminates parasitic loss of potentialenergy.

Energy-conversion system 200 includes controller 105. Energy-conversionsystem 200 also includes a reactor 210, also known as a conversionchamber or conversion reactor. Reactor 210 is an electrically controlledand electrically- or catalytically-heated reactor. Reactor 210 is achannel that is equipped with multi-zoned electric heat (e.g.,multi-zone heater 114). Namely, reactor 210 is enclosed withinmulti-zone heater 114. Further, reactor 210 in not limited to electricheat only. In another example, reactor 210 can be a catalytically-heatedreactor.

In one example, reactor 210 is a channel that is about 54 inches (about137.1 cm) wide, about 7 inches (about 17.78 cm) high, and about 75 feet(about 22.8 meters) long making multiple passes. However, reactor 210can be any dimensions. Namely, the length of reactor 210 may bedetermined by the amount of residence time needed in the system.Further, reactor 210 can be formed, for example, of carbon steel,stainless steel, or specialized alloys, such as, but not limited to,selected Inconel alloys. The system configuration of energy-conversionsystem 200 is particularly well suited for processing a homogenousfeedstock, such as manure or coal.

Further, instead of shaftless auger 112 shown in FIG. 1 , a dragconveyor 212 is installed in reactor 210 for moving the feedstock. Adrag conveyor (aka chain conveyor) is a conveyor in which an endlesschain, having wide links carrying projections or wings, is draggedthrough a trough into which the material to be conveyed is fed. A dragconveyor is generally used for moving loose material. Inenergy-conversion system 200, drag conveyor 212 is used to carryfeedstock through reactor 210. In reactor 210, drag conveyor 212 may beused to: (1) provide a large surface area for maximum thermal conduction(i.e., collectively, the links of the chain provide a large heatedsurface area), (2) allow for an adjustable bed depth of feedstock, and(3) minimize the drive horsepower requirement for conveyance. Using, forexample, manure feedstock in reactor 210, the feedstock bed depth ondrag conveyor 212 for optimal heat transfer (optimal cooking) is fromabout 4 inches (about 10.16 cm) to about 7 inches (about 17.78 cm) inone example, or is about 4.5 inches (about 11.43 cm) in another example.

Drag conveyor 212 may also be used for scouring the inside surfaces withflight design, which: (1) maximizes thermal conduction by minimizingmaterial deposits, and (2) minimizes rotational balling of material. Thecomponents of drag conveyor 212 can be formed of specialized alloys,such as, but not limited to, selected Inconel alloys. The use of thespecialized alloys (1) prevent galling of similar metals with directcontact, (2) prevent chlorine migration and hydrogen embrittlement, and(3) eliminate differential creep rate by controlling take up of the dragchain conveyor. However, in other embodiments, the components of dragconveyor 212 can be formed of carbon steel or stainless steel.

In energy-conversion system 200 and using drag conveyor 212, feedstockcan be conveyed through reactor 210 at high temperature if dissimilarmetals are utilized for all contact surfaces including chain pins,links, flights, and sprockets. The thermal creep growth can be addressedusing automatic tensioners on one end of drag conveyor 212. A multi-passdrag chain allows for feedstock advancement in both or opposingdirections on the same chain and creates the opportunity for prolongedresidence time, rotation, turning, and stirring of feedstock. Certainfeedstocks can experience a balling effect when conveyed using an auger,making uniform exposure to heat energy impossible. However, using dragconveyor 212, the feedstock bed depth can be adjusted to ensure uniformexposure without rotation, thereby eliminating the balling effect. Inconventional energy-conversion systems, drag chain conveyors have notbeen utilized due to galling and system airtight structure limits causedby pressure or vacuum.

Energy-conversion system 200 may also include the scale 116, mixer 118,feedstock hopper metering stage 120, in-feed sensors 122, and airlock124, wherein the scale 116, mixer 118, feedstock hopper metering stage120, in-feed sensors 122, and airlock 124 are used for processing thefeedstock (or in-feed) that supplies the inlet of reactor 210. Theoutlet of airlock 124 supplies the inlet of reactor 210.

Also different from energy-conversion system 100, feedstock hoppermetering stage 120 of energy-conversion system 200 features auger-lessin-feed metering; namely, a multi-metered, drag conveyor-based in-feedmechanism that includes a dryer. Conventional systems rely on batchfeeding or auger-driven in-feeds. Generally, systems are challengedeither by inconsistent characteristics of feedstock and/or extremelydifficult calculations to maintain an equal and consistent feed rate asmoisture, surface tension, density, temperature, and pressure are allvariables. A non-consistent feed rate can translate to inefficient,inconsistent, incomplete and/or over exposure to the heating andconversion process of the feedstock. To mitigate these drawbacks,feedstock hopper metering stage 120 of energy-conversion system 200provides the multi-metered, drag conveyor-based in-feed that creates auniform feedstock depth and width that maintains a balanced relationshipto the heat-source throughout the conveyance process. The feedstock issubjected to metering at the dryer and prior to entering reactor 210 toensure uniform and predictable bed depth. The customized dryer dragconveyer advances the uniformly shaped feedstock into a hot oil andsteric acid mixture or similar oil/acid mixture, high-temperature fluidbath (HTFB) 126 of airlock 124. Further, the dewatering airtight dragconveyor delivers the feedstock to the drag conveyor 212 in reactor 210.

Rather than using a conical auger, airlock 124 of energy-conversionsystem 200 includes the steric acid HTFB 126. Steric acid HTFB 126 canbe used to displace air without a vacuum pump or the addition of inertgas. Namely, using steric acid HTFB 126, the air in the feedstock isdisplaced with oil. The addition of steric acid to the HTFB acceleratesand intensifies the moisture flash-off, which increases thede-polymerization of complex hydrocarbons and minimizes the formation oftars and heavy oils. The hot oil, steric acid mixture HTFB 126 may beused to: (1) increase the density of feedstock without mechanicalinteraction, (2) create an airlock without need for valves orslide-gates, (3) eliminate any remaining moisture from feedstock, (4)increase the exposed surface area of the feedstock, and (5) maximize theheat transfer rate in reactor 210. Further, convention airlocks ofteninclude a negative-pressure vessel, which is a safety hazard and ahistoric point of failure. By contrast, hot oil, steric acid mixtureHTFB 126 does not require a negative-pressure vessel and therefore thesafety hazard and historic point of failure is eliminated.

In conventional reactor based conversion systems, feedstock moistureremoval has always been a challenge and often the fatal flaw. However,using steric acid HTFB 126, the “combustion-less flash-off” of allremaining moisture dramatically reduces both the time and the energyrequired to dry the feedstock, which in-turn dramatically improves theenergy balance and the economics. The steric acid also promotes theconversion of problematic tars and waxes into lighter, smaller carbonchains.

Airlock 124 eliminates all moving parts as feedstock is subjected to thehot liquid bath (of steric acid HTFB 126) displacing all air, flashingoff all remaining moisture, and allowing delivery to a dewateringconveyor of feedstock hopper metering stage 120. Feedstock is advancedpast the liquid barrier on the dewatering conveyor, which is an airlocksecondary metering device. The passive airlock system of airlock 124also creates a built-in pressure relief system for reactor 210. Further,the exhaust heat from the backend electricity generator can be cycledback to feedstock hopper metering stage 120 and/or airlock 124 and usedfor drying.

In summary with respect to feedstock hopper metering stage 120 andairlock 124, manure feedstock, for example, becomes fluffy and fibrouswhen dried, and full of air. Air is an insulator and prevents thefeedstock from heating. Accordingly, using feedstock hopper meteringstage 120 and airlock 124, (1) the manure feedstock becomes saturatedwith oil (e.g., mineral oil), which displaces the air and provides amedium that absorbs heat readily; (2) the density of the feedstockmaterial entering reactor 210 is increased; and (3) the manure feedstockthat is saturated with oil maximizes the contact ratio to the heatingmechanism (e.g., multi-zone heater 114) in reactor 210 (i.e., maximizesheat transfer rate between heater and feedstock). A further benefit ofhaving oil in the feedstock is that the latent energy required to driveout oil is about less than 95 BTU/pound. By contrast, the latent energyrequired to drive out water is much greater at about 950 BTU/pound.

Additionally, in energy-conversion system 200, rather than allowing thegas to exit the reactor to a separate quenching stage as described inFIG. 1 , a gas collection system is provided at a certain portion alongreactor 210. The gas collection system supplies a multi-zone quenchstation 214 that is integrated directly into reactor 210. The presenceof multi-zone quench station 214 eliminates the need for automatedplunging system 128. Multi-zone quench station 214 along with a quenchoil (Q-oil) filter 216 and an oil preheat stage 218 provides aclosed-loop arrangement wherein a quantity of circulating oil 220 iscirculated therethrough. Circulating oil 220 can be, for example,mineral oil or diesel fuel. Together, multi-zone quench station 214,Q-oil filter 216, oil preheat stage 218, and circulating oil 220 providea recirculating filtered hot oil quenching system that is used to removeany particulate prior to condensing. For example, circulating oil 220 iscirculated through multi-zone quench station 214, then through Q-oilfilter 216, then through oil preheat stage 218, then returning tomulti-zone quench station 214. Q-oil filter 216 is a commerciallyavailable continuous self-cleaning hot oil filter. The solids thataccumulate in Q-oil filter 216 can be fed back into the feedstock (orin-feed) and processed through reactor 210.

Using multi-zone quench station 214, hot circulating oil 220 isrecirculated back onto the gas in reactor 210 at about 300° F. (about149° C.), wherein oil preheat stage 218 is used to preheat circulatingoil 220 to the critical temperature for quenching, which is typicallyabout 300° F. (about 149° C.). In so doing, the gas is cooled to about300° F. (about 149° C.). Some portion of the cooled gas condenses andthe liquid recirculates. However, the lighter gases above about 300° F.(about 149° C.) that do not condense will pass onto the arrangement ofprimary compensator 136, primary recirculator 138, secondary compensator140, secondary recirculator 142, vacuum buffer tank 144, regulator 146,vacuum pump 148, syngas buffer tank 150, and catalytic scrub 152 asdescribed with reference to energy-conversion system 100 of FIG. 1 .Again, reactor 210 will be held at about 7 inches (about 17.78 cm) ofwater column pressure. Again, in energy-conversion system 200 there is atransition from a positive pressure system to a negative pressuresystem. Further, char 160 is discharged from one or more outlets ofreactor 210.

Referring now to FIG. 3 is a block diagram of an energy-conversionsystem 300 that includes a distillation and/or fractionating stage,according to yet another embodiment of the presently disclosedelectric-powered, electric- or catalytically-heated, closed-loop,continuous-feed, endothermic energy-conversion system. Energy-conversionsystem 300 is substantially the same as energy-conversion system 200 ofFIG. 2 except that it additionally includes an atmospheric fractionatingunit 230. Further, crude oil 220 is used for the circulating oil in themulti-zone quench station 214.

In pyrolysis, which is a thermochemical decomposition of organicmaterial at elevated temperatures in the absence of oxygen (or anyhalogen), there is always the generation of char, liquid, and syngas.However, coal feedstock produces a larger liquid and syngas fractionthan, for example, manure feedstock. The liquid fraction is needed toproduce, for example, gasoline, diesel, and/or asphalt. Accordingly,energy-conversion system 300 that includes the distillation and/orfractionating stage is particularly well suited for processing coalfeedstock.

In order to process the liquid fraction, energy-conversion system 300will typically include optional equipment to dilute the heavier liquidsresulting from some feedstocks. Accordingly, energy-conversion system300 includes the optional atmospheric fractionating unit 230 thatfurther includes a heavy oil fractionation process 232 and a gas-firedor catalytically-heated re-boiler 234. Further, diesel generated usingheavy oil fractionation process 232 is discharged to diesel storage 236.Likewise, asphalt generated using heavy oil fractionation process 232 isdischarged to asphalt storage 238.

Additionally, to support atmospheric fractionating unit 230,energy-conversion system 300 must provide a supply of additionaldiluting or cutting oil, such as crude oil 220. Further, inenergy-conversion system 300, if oil or gasoline is to be generated, thegasoline fraction is processed through the compensators (e.g., primarycompensator 136 and secondary compensator 140) while the diesel andheavy oils remain in the circulating oil. Additional separation can alsooccur through atmospheric fractionating unit 230. Namely, inenergy-conversion system 300, crude oil 220 is used as the circulatingoil for multi-zone quench station 214. In multi-zone quench station 214,oil preheat stage 218 is used to preheat crude oil 220 to the criticaltemperature for quenching, which is typically about 300° F. (about 149°C.). In reactor 210, as quenching occurs, vapor is also created, whereinthe lighter gases above about 300° F. (about 149° C.) that do notcondense will pass onto primary compensator 136. Namely, the gasolineand other light fractions are taken out of the crude oil. The gasolineand light fractions to pass through reactor 210 and are passed on to thearrangement of primary compensator 136, primary recirculator 138,secondary compensator 140, secondary recirculator 142, vacuum buffertank 144, regulator 146, vacuum pump 148, and syngas buffer tank 150,which supplies the gas-fired or catalytically-heated re-boiler 234. Inso doing, the gasoline and other light fractions are condensed anddischarged to, for example, gasoline storage 240 and other storage 242(e.g., water storage), wherein the gasoline and other light fractionscan be sold. Additionally, if stripping gas is required forfractionating, it can be blended with syngas and utilized in thegas-fired or catalytically-heated re-boiler 234.

In energy-conversion system 300, a portion (about half) of the crude oil220 circulating through multi-zone quench station 214 is pulled offdownstream of Q-oil filter 216 and supplied to the atmosphericfractionating unit 230 or any typical refining or fractionation system.Heavy oil fractionation process 232 of atmospheric fractionating unit230 is used to fractionate the oil using the syngas from syngas buffertank 150 and the gas-fired or catalytically-heated re-boiler 234. Heavyoil fractionation process 232 is used to break down the crude oil 220 toa diesel fraction and asphalt fraction, wherein the light fractions thattypically come off a refinery are recaptured into reactor 210. Thisallows the pressure in a fractionation tower to be maintained to thesame 7 inches (17.78 cm) of water column pressure that is in reactor210. In heavy oil fractionation process 232, the light fractions arecondensed and scrubbed. The gas, after it has been scrubbed, can beutilized in heavy oil fractionation process 232 as gas energy that isneeded to reheat the heavy oil fraction. Namely, heating to about 700°F. (about 371° C.), which allows separation into diesel and asphaltfractions.

Typical large-scale refineries operate under high temperatures and veryhigh pressure (many times atmospheric pressure) in the fractionationprocess. As a result, large-scale refineries include high temperatureprocesses and ultra-high pressure vessels that are highly regulated. Bycontrast, a main benefit of energy-conversion system 300 is thatatmospheric fractionating unit 230 operates at low temperature and atatmospheric pressure, wherein any vessels are not highly pressurized andtherefore are not typically subject to regulatory compliance. Namely,atmospheric fractionating unit 230 is called “atmospheric” because itoperates at or below atmospheric pressure, not at high pressure orultra-high pressure.

Further, in a gas-fired re-boiler much of the heat and most of thepollutants are lost up the stack. However, with respect to processingthe gas through a catalytically-heated re-boiler (e.g.,catalytically-heated re-boiler 234), the primary byproducts are carbondioxide (CO₂) and water (H₂O), which can be recaptured and therebyeliminating the requirement for a stack. The dioxide (CO₂) and water(H₂O) can be easily re-purposed for hydroponics, aquaculture, greenhouses, algae beds, and similar sustainable food initiatives. Inaggregate, the environmental efficiency (decreased pollution/increasedrecycling) of the catalytic conversion system is far superior to that ofthe gas-fired alternative

In summary, energy-conversion system 300 provides a process ofcommoditized natural resource recovery and refining. Namely, theun-gasified feedstock residual will consist of both a liquid fractionand a solid carbon char. The liquid fraction will resemble crude oil,which can be further refined into gasoline, diesel fuel, or naphthabased on end-user specification. The solids fraction will be a carbonchar that can prescriptively bond to and/or chelate any commoditizednatural resources present in the feedstock, such as nitrogen,phosphorus, zinc, manganese, magnesium. The resulting char can then bere-formatted for beneficial reuse as a soil amendment, or due to itspathogen-free, medical residual-free status, as a high-end animal feedsupplement. Further, energy-conversion system 300 features integrationof selective fractional condensing. Namely, through a series ofquenchings with a proprietary combination of circulating fluids, and theutilization of compensators at critical temperatures ranges, the liquidfraction of the processed feedstock can yield fractionated productsincluding, but not limited to, gasoline, diesel, heavy fuel oil,asphaltenes, and lubricants which can be stored on-site in tanks ortransported off-site by truck, rail, or pipeline.

FIG. 4 through FIG. 25 show various views of one example instantiationof the shaftless auger-based energy-conversion system 100 shown in FIG.1 . Namely, FIG. 4 , FIG. 5 , and FIG. 6 show an isometric view, a sideview, and a top down view, respectively, of energy-conversion system 100in its entirety. FIG. 7 through FIG. 25 show various portions of theshaftless auger-based energy-conversion system 100 shown in FIG. 1 . Forexample, FIG. 7 shows an isometric view and FIG. 8 shows a front viewand a top down view of the reactor 110 and multi-zone heater 114 portionof energy-conversion system 100. FIG. 9 and FIG. 10 show variouscross-sectional views of the reactor 110 and multi-zone heater114-portion of energy-conversion system 100 and now showing shaftlessauger 112. FIG. 11 shows an isometric view and FIG. 12 shows a frontview and a top down view of the reactor 110-portion of energy-conversionsystem 100. FIG. 13 and FIG. 14 show cross-sectional views of thereactor 110-portion of energy-conversion system 100 and now showingshaftless auger 112. FIG. 15 shows an isometric view and an end view ofthe multi-zone heater 114-portion of energy-conversion system 100. FIG.16 shows a front view and a top down view of the multi-zone heater114-portion of energy-conversion system 100.

FIG. 17 shows an isometric view, a front view, and a side view of theprimary compensator 136-portion of energy-conversion system 100. FIG. 18shows an isometric view, FIG. 19 shows a top down view, and FIG. 20shows a front view and a side view of the ceramic hot gas filter130-portion of energy-conversion system 100. FIG. 21 shows an isometricview, a front view, and a side view of the primary recirculator138-portion of energy-conversion system 100.

The multi-tube plunging condenser 133 of energy-conversion system 100includes a condenser portion and a hydraulic or pneumatic plungingportion. For example, FIG. 22 shows an isometric view and FIG. 23 showsa side view and a cross-sectional view of a condensing unit 133′ ofmulti-tube plunging condenser 133, while FIG. 24 and FIG. 25 show anisometric view and an end view, respectively, of a hydraulic orpneumatic plunging unit 133″ (e.g., hydraulic cylinders) of multi-tubeplunging condenser 133. Condensing unit 133′ and hydraulic or pneumaticplunging unit 133″ are arranged end-to-end to form multi-tube plungingcondenser 133 (see FIG. 4 , FIG. 5 , and FIG. 6 ).

Referring now to FIG. 26 is a flow diagram of a method 400, which is anexample of a method of operation of energy-conversion system 100 thatincludes shaftless auger 112 installed in reactor 110. Method 400 mayinclude, but is not limited to, the following steps.

At a step 410, an energy-conversion system is provided that includes ashaftless auger. For example, energy-conversion system 100 is providedthat includes shaftless auger 112 installed in reactor 110 and allheated using multi-zone heater 114.

At a step 415, feedstock material is supplied to energy-conversionsystem 100. For example, feedstock material, such as, but not limitedto, any biomass (e g, manure, coal, trash, rubber, and plastic), miningwaste (e.g., mine tailings and water-based and/or oil-based drillingmud), and “sticky” feedstock (e.g., rubber and plastic), can be receivedand weighed at scale 116 and then fed into mixer 118 that ensures ahomogenous mixture.

At a step 420, the feedstock material is processed and then supplied tothe inlet of the reactor. For example, the feedstock material is fedinto feedstock hopper metering stage 120 for metering the feedstock intoreactor 110 at a certain rate. Namely, feedstock hopper metering stage120 is used to pre-heat and dry the feedstock. Further, in-feed sensors122 are used to automatically control feedstock bed-depth and rate intoreactor 110. Feedstock hopper metering stage 120 supplies the feedstockto airlock 124 that is used to compress the feedstock material (i.e.,remove the air from the feedstock).

At a step 425, the feedstock material is advanced through the reactorwhile the reactor facilitates a phase-change process of the feedstockfrom solid to liquid to vapor. For example, using shaftless auger 112,feedstock is advanced and processed through reactor 110, wherein reactor110 facilitates the phase-change process of the feedstock from solid toliquid to vapor. Namely, multi-zone heater 114 is activated and used tomaintain accurate and consistent temperature within reactor 110.Increased heat transfer rates are achieved by the large amount ofsurface contact created by the increased density of feedstock withliquid increasing the phase-change process to vapor. Continuous processvapor is mixed throughout the process and equalized prior to reachingthe outlets. Pressure is maintained within reactor 110 with vaporcreated in phase change of the feedstock.

At a step 430, both char and vapor are discharged from respectiveoutlets of the reactor. For example, char 160 is one output of reactor110 of energy-conversion system 100 while vapor is another output ofoutput of reactor 110 that is further processed.

At a step 435, particulates are removed from the vapor discharged fromthe reactor. For example, vapor that is at a critical heat temperatureof, for example, from about 900° F. (about 482° C.) to about 1000° F.(about 538° C.) exits reactor 110 through ceramic hot gas filter 130,wherein ceramic hot gas filter 130 provides active vapor filtration toremove any particulate prior to condensing.

At a step 440, vapor quenching operations are performed whereinmechanisms are provided for preventing tar, grease, and/or waxbuild-ups. For example, quenching of vapor with produced liquid fractionproduct is accomplished using first quench stage 132 and second quenchstage 134. Quenching promotes the elimination of tars, resins, and waxes(i.e., the heavy tars or oils) in gas fraction, removes particulate forthe vapor stream, and allows for collection of specific fraction ofcondensable liquid. The vapor can be quenched using, for example,mineral oil or any other oil that can be used to absorb the tars,resins, and waxes.

At a step 445, after quenching, energy-conversion system 100 transitionsfrom a positive pressure system to a negative pressure system. Forexample, after quenching, primary compensator 136 and secondarycompensator 140 allow a continuous flow transition of the reactor vaporfrom positive pressure to negative pressure, acting as a systemnon-clogging or sticking pressure regulator.

At a step 450, the vapor is supplied to the vacuum buffer tank. Forexample, using primary compensator 136 and primary recirculator 138followed by secondary compensator 140 and secondary recirculator 142,anything that is condensable is condensed so that vapor only moves on tovacuum buffer tank 144.

At a step 455, liquid is removed from the vapor and the vapor is cooled.For example, vapor passes from vacuum buffer tank 144 to vacuum pump 148via regulator 146. Then, vacuum pump 148 is used to remove liquid fromvapor and to cool gas on the pressure side of the vacuum. In vacuum pump148, the fluid is chilled by heat exchange.

At a step 460, a filter-less quenching gas cleanup operation isperformed and gas is discharged. For example, vacuum pump 148 suppliessyngas buffer tank 150 which then supplies catalytic scrub 152.Catalytic scrub 152 performs a gas polishing operation that ensures highquality gas in which sulfur, chlorine, and other gas contaminants havebeen substantially eliminated. In this way, energy-conversion system 100is used to produce high quality syngas, or synthesis gas, which is afuel gas mixture consisting primarily of hydrogen, carbon, methane,propane, butane, carbon monoxide, and very often some carbon dioxide.

At a step 465, throughout all of the operations of method 400,energy-conversion system 100 is continuously balanced. For example, thecombination of vacuum buffer tank 144 on the upstream side of vacuumpump 148 and the pressurized syngas buffer tank 150 on the downstreamside of vacuum pump 148 provides a control loop for balancing thesystem. In another mechanism, primary compensator 136 and secondarycompensator 140 in combination with the vacuum buffer tank 144-vacuumpump 148-syngas buffer tank 150 loop is the mechanism used to controlthe pressure inside reactor 110. For example, this control loop can beused to hold the pressure inside reactor 110 at about 7 inches (about17.78 cm) of water column.

FIG. 27 through FIG. 56 show various views of one example instantiationof the drag conveyor-based energy-conversion system 200 shown in FIG. 2. Namely, FIG. 27 , FIG. 28 , FIG. 29 , and FIG. 30 show an isometricview, a top down view, a side view, and an end view, respectively, ofenergy-conversion system 200 in its entirety. FIG. 31 , FIG. 32 , FIG.33 , and FIG. 34 show the same views of energy-conversion system 200 asshown in FIG. 27 , FIG. 28 , FIG. 29 , and FIG. 30 , respectively, butsimplified.

In energy-conversion system 200, feedstock hopper metering stage 120includes a dryer and a drag conveyor, as shown in FIG. 35 through FIG.39 . Namely, FIG. 35 , FIG. 36 , and FIG. 37 show an isometric view, aside view, and a top down view, respectively, of the feedstock hoppermetering stage 120-potion of energy-conversion system 200. FIG. 38 andFIG. 39 show cross-sectional views of the feedstock hopper meteringstage 120-potion of energy-conversion system 200 and now showing a dragconveyor 206 enclosed therein.

FIG. 40 , FIG. 41 , and FIG. 42 show an isometric view, a side view, anda top down view of the airlock 124-potion of energy-conversion system200. FIG. 43 and FIG. 44 show cross-sectional views of the airlock124-potion of energy-conversion system 200 and now showing a dragconveyor 208 enclosed therein.

FIG. 45 , FIG. 46 , and FIG. 47 show an isometric view, a side view, anda top view, respectively, of multi-zone heater 114 of energy-conversionsystem 200, wherein reactor 210 (not visible) is enclosed withinmulti-zone heater 114. Further, FIG. 48 and FIG. 49 show cross-sectionalviews of multi-zone heater 114 and showing reactor 210, wherein dragconveyor 212 is arranged within reactor 210. Additionally, FIG. 50 ,FIG. 51 , and FIG. 52 show close-up cross-section views of a portion ofmulti-zone heater 114 and showing more details of reactor 210 and dragconveyor 212. Further, FIG. 53 shows an isometric view and FIG. 54 showsa side view and a top down view of reactor 210 absent multi-zone heater114. Similarly, FIG. 55 and FIG. 56 show cross-sectional views ofreactor 210 and drag conveyor 212 absent multi-zone heater 114.

Following long-standing patent law convention, the terms “a,” “an,” and“the” refer to “one or more” when used in this application, includingthe claims. Thus, for example, reference to “a subject” includes aplurality of subjects, unless the context clearly is to the contrary(e.g., a plurality of subjects), and so forth.

Throughout this specification and the claims, the terms “comprise,”“comprises,” and “comprising” are used in a non-exclusive sense, exceptwhere the context requires otherwise. Likewise, the term “include” andits grammatical variants are intended to be non-limiting, such thatrecitation of items in a list is not to the exclusion of other likeitems that can be substituted or added to the listed items.

For the purposes of this specification and appended claims, unlessotherwise indicated, all numbers expressing amounts, sizes, dimensions,proportions, shapes, formulations, parameters, percentages, quantities,characteristics, and other numerical values used in the specificationand claims, are to be understood as being modified in all instances bythe term “about” even though the term “about” may not expressly appearwith the value, amount or range. Accordingly, unless indicated to thecontrary, the numerical parameters set forth in the followingspecification and attached claims are not and need not be exact, but maybe approximate and/or larger or smaller as desired, reflectingtolerances, conversion factors, rounding off, measurement error and thelike, and other factors known to those of skill in the art depending onthe desired properties sought to be obtained by the presently disclosedsubject matter. For example, the term “about,” when referring to a valuecan be meant to encompass variations of, in some embodiments, ±100% insome embodiments ±50%, in some embodiments ±20%, in some embodiments±10%, in some embodiments ±5%, in some embodiments ±1%, in someembodiments ±0.5%, and in some embodiments ±0.1% from the specifiedamount, as such variations are appropriate to perform the disclosedmethods or employ the disclosed compositions.

Further, the term “about” when used in connection with one or morenumbers or numerical ranges, should be understood to refer to all suchnumbers, including all numbers in a range and modifies that range byextending the boundaries above and below the numerical values set forth.The recitation of numerical ranges by endpoints includes all numbers,e.g., whole integers, including fractions thereof, subsumed within thatrange (for example, the recitation of 1 to 5 includes 1, 2, 3, 4, and 5,as well as fractions thereof, e.g., 1.5, 2.25, 3.75, 4.1, and the like)and any range within that range.

Although the foregoing subject matter has been described in some detailby way of illustration and example for purposes of clarity ofunderstanding, it will be understood by those skilled in the art thatcertain changes and modifications can be practiced within the scope ofthe invention.

That which is claimed:
 1. A system for converting energy comprising: acontroller; a reactor having inner walls operated by the controller; adrag conveyor in the reactor, the drag conveyor including a multi-passdrag chain adapted to allow a feedstock material to advance in opposingdirections on the same drag chain; and a multi-zone heater surroundingthe reactor and the drag conveyor.
 2. The system of claim 1, furthercomprising an airlock having a steric acid high-temperature fluid bathforming a closed loop with the reactor.
 3. The system of claim 2,wherein the closed loop further comprises a multi-zone quench stationhaving a quench oil filter and an oil preheated stage.
 4. The system ofclaim 3, wherein the closed loop further comprises an atmosphericfractioning unit.
 5. The system of claim 4, wherein the atmosphericfractioning unit comprises a heavy oil fractioning process, a re-boiler,a diesel storage, and an asphalt storage, wherein the multi-zone quenchstation includes a supply of diluting oil.
 6. A method for convertingenergy, comprising the steps of: providing an energy conversion systemaccording to claim 1; supplying feedstock material to theenergy-conversion system; processing the feedstock material; supplyingthe processed feedstock material to the inlet of the reactor; advancingthe processed feedstock through the reactor while the reactorfacilitates a phase-change process of the feedstock from solid to liquidto vapor; maintaining through the heater accurate and consistenttemperature within reactor; maintaining a positive pressure in theenergy-conversion system; discharging from reactor outlets char andvapor obtained from the reacted feedstock; removing particulates fromthe discharged vapor; quenching the discharged vapor to prevent tar,grease, and/or wax build-ups; after the quenching step, transitioningfrom the positive pressure to a negative pressure in theenergy-conversion system; and supplying the quenched vapor to a vacuumbuffer tank.
 7. The method of claim 6, further comprising the steps of:advancing the supplied vapor to a regulator; removing liquid from theadvanced vapor; cooling the advanced vapor; and performing a filter-lessquenching gas clean-up operation on the advanced vapor; and forming anddischarging syngas.
 8. The method of claim 6, further comprising thestep of advancing the reacted feedstock to a quench station.
 9. Themethod of claim 8, further comprising the step of advancing the quenchedfeedstock to an atmospheric fractioning unit.
 10. The method of claim 6,further comprising the steps of advancing the reacted feedstock to anautomated plunging system.